Method of forming flow-fill structures

ABSTRACT

A preferred embodiment of the invention is directed to support structures such as spacers used to provide a uniform distance between two layers of a device. In accordance with a preferred embodiment, the spacers may be formed utilizing flow-fill deposition of a wet film in the form of a precursor such as silicon dioxide. Formation of spacers in this manner provides a homogenous amorphous support structure that may be used to provide necessary spacing between layers of a device such as a flat panel display.

[0001] 250 microns (about 0.010 inches), electrical breakdown occurred within a range of 1,100 to 1,400 volts. All other parameters remaining constant, breakdown voltage will rise as the separation between screen and cathode array is increased. However, maintaining uniform separation between the screen and the cathode array is complicated by the need to evacuate the cavity between the screen and the cathode array to a pressure of less than 10⁻⁶ Torr to enable field emission.

[0002] Small area displays (for example, those which have a diagonal measurement of less than 3 centimeters) can be cantilevered from edge to edge, relying on the strength of a glass screen having a thickness of about 1.25 millimeters to maintain separation between the screen and the cathode array. Since the displays are small, there is no significant screen deflection in spite of the atmospheric load. However, as display size is increased, the thickness of a cantilevered flat glass screen must be increased exponentially. For example, a large rectangular television screen measuring 45.72 centimeters (18 inches) by 60.96 centimeters (24 inches) and having a diagonal measurement of 76.2 centimeters (30 inches), must support an atmospheric load of at least 28,149 Newtons (6,350 pounds) without significant deflection. A glass screen (also known as a “faceplate”) having a thickness of at least 7.5 centimeters (about 3 inches) might well be required for such an application. Moreover, the cathode array structure must also withstand a like force without deflection.

[0003] A solution to cantilevered screens and cantilevered cathode array structures is the use of closely spaced, load-bearing, dielectric (or very slightly conductive, e.g., resistance greater than 10 mega-ohm) spacer structures. Each of the load-bearing structures bears against both the screen and the cathode array plate and thus maintains the two plates at a uniform distance between one another. By using load-bearing spacers, large area evacuated displays might be manufactured with little or no increase in the thickness of the cathode array plate and the screen plate.

SUMMARY OF THE INVENTION

[0004] A preferred embodiment of the invention is directed to support structures such as spacers or other layers of fixed geometry used to provide a uniform distance between two layers of a device. In accordance with a preferred embodiment, the spacers may be formed utilizing flow-fill deposition of a wet film in the form of a precursor such as silicon dioxide. Formation of spacers in this manner provides a homogenous amorphous support structure that may be used to provide necessary spacing between layers of a device such as a flat panel display.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Many advantages, features, and applications of the invention will be apparent from the following detailed description of the invention that is provided in connection with the accompanying drawings in which:

[0006] FIGS. 1-6 illustrate a cross-sectional view of a device under fabrication in accordance with a preferred embodiment of the invention;

[0007] FIGS. 7(a), 7(b), and 7(c) illustrate cross-sectional views of additional devices fabricated in accordance with preferred embodiments of the invention;

[0008] FIGS. 8(a) and 8(b) are top views of a spacer formed in accordance with a preferred embodiment of the invention;

[0009]FIG. 9 is a cross-sectional view of a device employing a plurality of spacers in accordance with a preferred embodiment of the invention;

[0010]FIG. 10 is a cross-sectional view of a flat panel display in accordance with a preferred embodiment of the invention; and

[0011]FIG. 11 is a processor system in accordance with a preferred embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0012] Preferred embodiments and applications of the invention will now be described with reference to FIGS. 1-11. Other embodiments may be realized and structural or logical changes may be made to the disclosed embodiments without departing from the spirit or scope of the invention. Although the invention is particularly described as applied to spacers for use in a flat panel display, it should be readily apparent that the invention may be embodied in any device or system having the same or similar problems.

[0013] A method in accordance with a preferred embodiment of the invention can be used to form a support structure for use in providing support or maintaining a given distance between two layers of a device. As an illustration, a preferred embodiment of the invention is employed to fabricate a support structure (or other layers of fixed geometry) in the form of one or more spacers 16 used to maintain separation between two layers 21, 22 of a device 200, as shown in FIG. 6. A method of fabricating such a device in accordance with a preferred embodiment of the invention begins with the preparation of the layer (21 or 22) of the device which will initially support the spacer. For the device layer chosen, a substrate 10 of suitable material (e.g., silicon wafer, glass, etc.) is provided, as shown in FIG. 1. In accordance with a preferred embodiment, a photosensitive coating material such as photoresist layer 12 is applied in well-known fashion to the top surface of substrate 10.

[0014] In a preferred embodiment, a mask or reticle is used to define regions where the structures will be formed. An intense light source is then provided to expose certain portions of layer 12 and after developing the photoresist, openings or similar areas within first layer 12 are created. These openings in first layer 12 will shape the support structures to be formed on substrate 10.

[0015] In this illustrative embodiment, it is assumed that openings 18 (FIG. 2) formed in this manner in first layer 12 preferably expose the top surface of substrate 10 and provide the shape of columns, rods, or other post-like structures. In this illustrated embodiment, these structures have a substantially circular cross-section normal to the top surface of substrate 10. As will be evident below, however, any useful geometrical shape or orientation relative to substrate 10 may be achieved in accordance with the invention.

[0016] The device layer (21, 22) used as the initial support layer containing substrate 10, first layer 12, is “developed” using any of the well known fabrication techniques to remove the exposed photoresist and harden the remaining photoresist layer areas 12 a (FIG. 2). Any additional steps known in the art can be utilized as necessary to remove any areas not covered by the hardened photoresist utilizing, for example, chemical solution or plasma (gas discharge) to etch away the extraneous material.

[0017] As shown in FIG. 3, a precursor material 16 is then deposited over first layer 12 and within openings 18. In accordance with a preferred embodiment of the invention, a “flow-fill” deposition technique, as described in Dobson et al., “Advanced SiO₂ Planarization Using Silane and H₂O₂,” Semiconductor International, December 1994, pp. 85-88, and Gaillard et al., “Silicon Dioxide Chemical Vapor Deposition Using Silane and Hydrogen Peroxide,” J. Vac. Sci. Technology, B 14(4), July/August 1996, pp. 2767-2769, which are both incorporated herein by reference in their entireties, is utilized to produce a homogenous and amorphous structure formed on substrate 10 at locations marked by openings 18.

[0018] In accordance with a preferred embodiment of the invention, the flow-fill deposition of layer 16 involves an initial cooling of substrate 10 (in a temperature range of 0-50° C., for this illustrated embodiment). Two separated reactive gases (e.g., one bearing silane (SiH₄) and the other bearing hydrogen peroxide (H₂O₂) and water) are then mixed to form a liquid glass layer to produce a wet film of sol-gel precursor (Si(OH₄) and various dehydrated oligomers). This wet film is deposited over photoresist layer 12, filling the trenches provided by openings 18, as shown in FIG. 3. An additional baking or annealing step may be supplied to further harden the precursor layer. Furthermore, an expulsion step may be added to remove quantities of water from the spacers in accordance with the following reaction:

H[OSi(OH₂)]_(n)OH→nSiO₂+(n+1)H₂O.

[0019] In accordance with a preferred embodiment, the device layer (21, 22) is then planarized utilizing any of the known techniques such as etching or chemical mechanical polishing (CMP). The planarization is performed to remove any portion of precursor 16 which extends beyond the height or level of photoresist layer 12, thus leaving the precursor only within openings 18, as shown in FIG. 4. Resist removal is performed using techniques well known in the art to strip photoresist layer 12 from the surface of substrate 10, leaving only the silicon dioxide spacers formed (in this illustrated embodiment) as one or more columns 16, as shown in FIG. 5. The device layer (21, 22) having the spacers 16 formed thereon can then be assembled with the other layer (21, 22) to form a multi-layer device having two layers 21, 22 separated by one or more spacers 16, as shown in FIG. 6.

[0020] The support structure represented by spacer 16 in the embodiments described above can be formed as any one of a variety of different shapes and sizes in accordance with the preferred embodiments illustrated above. For example, the spacer can be formed as an I-shaped (or approximately I-shaped) structure 126 having wide end portions coupled to layers 21 and 22, as shown in FIG. 7(a). The spacer can also be formed in a T-shaped (or approximately T-shaped) structure with a wide end portion coupled to support layer 21 and a narrow end portion coupled to support layer 22, as shown by spacer 136 in FIG. 7(b), or alternatively, with a wide end portion coupled to support layer 22 and a narrow end portion coupled to support layer 21, as shown by spacer 146 in FIG. 7(c). The spacer can further be formed in an X-shaped structure 156, as shown in FIGS. 8(a) and 8(b).

[0021] When used to support or separate layers 21, 22 of a device, as discussed above, the spacers formed in accordance with a preferred embodiment of the invention are preferably uniformly distributed or located throughout the device, or may be irregularly distributed as desired. The spacers may have identical geometries (e.g., circular columns, X-shaped posts, etc.) with identical orientations, or may be varied in both geometry and orientation among the plurality of spacers used in the device. Moreover, the spacers formed in accordance with a preferred embodiment of the invention may be varied in height. For example, as shown by spacers 114, 116 in FIG. 9, spacers 116 in the center of the device may be longer than spacers 114 located toward the edges of the device.

[0022] As illustrated in FIG. 10, spacer 116 formed in accordance with a preferred embodiment of the invention may be employed in a device such as flat panel display 400. As depicted in FIG. 10, flat panel display 400 is representative of a typical flat panel display having cathode 121 and anode 122. Cathode 121 is typically composed of substrate 111 made of single crystal silicon or glass. A conductive layer 112, such as doped polysilicon or aluminum, is formed on substrate 111. Conical emitters 113 are formed on conductive layers 112. Surrounding emitters 113 are a dielectric layer 114 and a conductive extraction grid 115 formed over dielectric layer 114. A power source 120 is typically provided to apply a voltage differential between conductive layers 112 and grid 115 such that electrons 117 bombard pixels 124 of anode (faceplate) 122. Faceplate 122 typically employs a transparent dielectric 196, a transparent conductive layer 198, and a black matrix grille (not shown) formed over conductive layer 198 for defining regions for phosphor coating.

[0023] In accordance with a preferred embodiment of the invention, spacer 166 may be formed on, for example, a support layer in the form of anode (or faceplate) 122 during fabrication of faceplate 122 for use in flat panel display 400. After formation of spacer 166 and faceplate 122, flat panel display 400 can be assembled by joining faceplate 122 and cathode 121 together as separated by spacers 166, as shown in FIG. 10, and the display vacuum sealed in a manner well known in the art.

[0024] The flat panel display (FPD) 400 thus assembled in accordance with a preferred embodiment of the invention may be utilized as a display device in a processor system 600, as shown in FIG. 11. In accordance with a preferred embodiment, processor-based system 600 may be a computer system, a process control system, or any other system employing a processor and associated display devices. The processor-based system includes a central processing unit (CPU) 470 (e.g., microprocessor) that communicates with I/O device 410 over bus 440. The processor-based system 600 also includes random access memory (RAM) 420, read only memory (ROM) 430, CD ROM drive 450, floppy disk drive 460, and hard drive 465 which all communicate with CPU 470 (and each other) over bus 440 in a manner well known in the art.

[0025] While preferred embodiments of the invention have been described and illustrated, it should be apparent that many modifications to the embodiments and implementations of the invention can be made without departing from the spirit or scope of the invention. For example, the spacers may be coupled directly to faceplate and grid 115, as shown in FIG. 10 (or directly on substrate 111) of cathode 121. Although in the embodiments illustrated above it was assumed that the anode or faceplate layer of the flat panel display was to be used as the initial supporting structure, it is understood that the cathode could alternatively be used as the initial supporting structure. Although the use of a single photosensitive material in the form of photoresist layer 12 (FIG. 1) was utilized in the illustrated embodiments, it should be apparent that other photoresist layers or multiple photoresist layers (negative or positive resists) could be used for creating the desired geometrical shape openings in photoresist layer 12 in accordance with the invention.

[0026] Typically, the Novolac or phenolic-type resin used in display manufacturing exhibits hydroxyl functions which will promote wetting of the flow-fill film layer employed in the illustrated embodiments described above. As an alternative, the resin may be pretreated with a conformal layer of chemical vapor deposit (CVD) oxide or other layer before the flow-fill deposition step is performed. In addition, the wet film used in the “flow-fill” deposition step may be obtained as a byproduct in the reaction of tetraethyloxysilicate (TEOS) with H₂O and optionally N₂O, O₂, O₃, H₂O₂.

[0027] Moreover, the initial device layer (e.g., the faceplate) may be prepared by depositing an underlayer using plasma enhanced chemical vapor deposition (PECVD) prior to performing the flow-fill depositing step. The same (or similar) PECVD process may be used to provide an oxide capping layer over the spacers on the initial device (or faceplate) layer after the flow-fill depositing step. In addition, it should be readily apparent that the flow-fill deposition step illustrated above may also involve other glass-like material such as B or P doped SiO₂. 

What is claimed as new and desired to be protected by Letters Patent of the United States is:
 1. A method of forming a layer of fixed geometry for use in a device having at least two device layers, the method comprising the steps of: providing a substrate for the device; and depositing a precursor in a substantially liquid form on a top surface of the substrate to form at least one layer of fixed geometry.
 2. The method of forming a layer of fixed geometry as set forth in claim 1, wherein said step of depositing a precursor comprises the substep of flow-fill depositing a sol-gel precursor.
 3. The method of forming a layer of fixed geometry as set forth in claim 2, wherein the precursor in said step of depositing is silicon dioxide (SiO₂).
 4. The method of forming a layer of fixed geometry as set forth in claim 3, wherein the flow-fill depositing substep is performed using a wet film obtained as a byproduct in the reaction of tetraethyloxysilicate (TEOS) with H₂O.
 5. The method of forming a layer of fixed geometry as set forth in claim 4, wherein the reaction in said flow-fill depositing substep is a reaction of TEOS with H₂O and O₂, N₂O, O₃, H₂O₂.
 6. The method of forming a layer of fixed geometry as set forth in claim 3, wherein the flow-fill depositing substep is performed using a growth of SiO₂ obtained from a mixture of SiH₄+H₂O₂ and H₂O.
 7. The method of forming a layer of fixed geometry as set forth in claim 6, wherein the mixture in said flow-fill depositing substep is a mixture of SiH₄+H₂O₂, O₂, N₂O, O₃, and H₂O.
 8. The method of forming a layer of fixed geometry as set forth in claim 1, wherein the device is a flat panel display composed of a cathode and a faceplate; wherein the faceplate is composed of the substrate provided in said providing step and a conductive layer; and wherein the at least one layer of fixed geometry is formed as at least one spacer on the faceplate of the flat panel display for maintaining a distance between the cathode and the faceplate in the flat panel display.
 9. The method of forming a layer of fixed geometry as set forth in claim 8, wherein said depositing step further comprises the substep of forming a plurality of spacers uniformly deposited on the substrate.
 10. The method of forming a layer of fixed geometry as set forth in claim 8, wherein said depositing step further comprises the substep of forming at least one spacer having a circular cross-sectional shape normal to a top surface of the substrate.
 11. The method of forming a layer of fixed geometry as set forth in claim 8, wherein said depositing step further comprises the substep of forming at least one spacer having an approximately I-shaped spacer.
 12. The method of forming a layer of fixed geometry as set forth in claim 8, wherein said depositing step further comprises the substep of forming at least one spacer having an approximately T-shaped spacer.
 13. A method of fabricating a flat panel display having a cathode and a faceplate, the method comprising the steps of: depositing a first layer of photoresist on the faceplate; depositing a patterned second layer of photoresist on the first layer of photoresist, the second layer covering selected portions of the first layer of photoresist; providing a light source to expose the second layer of photoresist and portions of the first layer of photoresist not covered by the second layer of photoresist so as to form openings in the first layer that expose portions of the faceplate; flow-fill depositing a wet film of sol-gel precursor made of silicon dioxide (SiO₂) on a top surface of the first layer of photoresist and in the openings in the first layer; baking the precursor so as to form spacers in the form of SiO₂-filled columns in the openings in the first layer of photoresist; planarizing the precursor to remove the precursor on the first layer of photoresist while leaving the precursor filled in the openings in the first layer; stripping the first layer of photoresist leaving the SiO₂-filled columns as spacers on the faceplate; and assembling the flat panel display with the cathode and the faceplate separated by the spacers.
 14. The method of fabricating a flat panel display as recited in claim 13, wherein said flow-fill depositing step is performed using a wet film in the form of a liquid obtained as a byproduct in the reaction of tetraethyloxysilicate (TEOS) with H₂O.
 15. The method of fabricating a flat panel display as recited in claim 14, wherein the reaction in said flow-fill depositing substep is a reaction of TEOS with H₂O and O₂, N₂O, O₃, H₂O₂.
 16. The method of fabricating a flat panel display as recited in claim 13, wherein said flow-fill depositing step is performed using a growth of SiO₂ obtained from a mixture of SiH₄+H₂O₂ and H₂O.
 17. The method of fabricating a flat panel display as recited in claim 16, wherein the flow-fill depositing substep is performed using a growth of SiO₂ obtained from a mixture of SiH₄+H₂O₂, O₂, N₂O, O₃, and H₂O.
 18. The method of fabricating a flat panel display as recited in claim 13, wherein said flow-fill depositing step further comprises the substep of providing separated reactive gas trains, one bearing silane (SiH₄) and the other bearing hydrogen peroxide (H₂O₂), which are then mixed to form the silicon dioxide (Si(OH₄)) precursor.
 19. The method of fabricating a flat panel display as recited in claim 18, wherein one of the reactive gas trains bears is bearing hydrogen peroxide (H₂O₂), N₂O, O₂, H₂O₂ O₃.
 20. The method of fabricating a flat panel display as recited in claim 13, wherein said flow-fil1 depositing step further comprises the substep of providing glass-like material in the form of doped SiO₂.
 21. The method of fabricating a flat panel display as recited in claim 13, wherein an oxide capping layer is applied to the spacers on the faceplate using plasma enhanced chemical vapor deposition (PECVD) after said flow-filling depositing step is performed.
 22. The method of fabricating a flat panel display as recited in claim 13, further comprising the step of expulsion of quantities of water from the spacers in accordance with the following reaction: H[OSi(OH₂)]_(n)OH→nSiO₂+(n+1)H₂O.
 23. The method of fabricating a flat panel display as recited in claim 13, wherein the faceplate is prepared by depositing an underlayer using plasma enhanced chemical vapor deposition (PECVD) prior to said flow-filling depositing step.
 24. The method of fabricating a flat panel display as recited in claim 22, wherein the faceplate is prepared by depositing an underlayer using plasma enhanced chemical vapor deposition (PECVD) prior to said flow-filling depositing step.
 25. The method of fabricating a flat panel display as recited in claim 13, wherein the said assembling step further comprises the substep of vacuum sealing the flat panel display.
 26. The method of fabricating a flat panel display as recited in claim 13, wherein the spacers are X-shaped.
 27. A multi-layer device comprising: a first device layer; a second device layer; and at least one flow-fill structure in the form of a spacer providing a minimum distance between said first and second device layers.
 28. The multi-layer device as recited in claim 27, wherein said at least one spacer is one of a plurality of homogenous amorphous spacers provided at uniform distances from each other throughout the multi-layer device.
 29. The multi-layer device as recited in claim 28, wherein the plurality of spacers have different heights.
 30. The multi-layer device as recited in claim 29, wherein spacers in a center position in the multi-layer device are higher than spacers at side positions of the multi-layer device.
 31. The multi-layer device as recited in claim 27, wherein said at least one spacer is shaped as a rod positioned substantially normal to a top surface plane of said second device layer.
 32. The multi-layer device as recited in claim 27, wherein said at least one spacer has an approximately I-shaped structure.
 33. The multi-layer device as recited in claim 27, wherein said at least one spacer has an approximately T-shaped structure.
 34. The multi-layer device as recited in claim 33, wherein a wider end portion of the approximately T-shaped structure of said at least one spacer is coupled to said second device layer.
 35. The multi-layer device as recited in claim 33, wherein a wider end portion of the T-shape structure of said at least one spacer is coupled to said first device layer.
 36. The multi-layer device as recited in claim 27, wherein the device is a flat panel display, where said second device layer is a faceplate substrate having a conductive layer formed thereon, and wherein said at least one spacer is formed directly on the faceplate substrate.
 37. A processor system comprising: a processor; and a flat panel display, wherein said flat panel display comprises: a cathode; an anode; and at least one homogenous amorphous flow-fill deposited spacer providing a minimum distance between said cathode and said anode.
 38. The flat panel display as recited in claim 37, wherein said at least one spacer is one of a plurality of homogenous amorphous spacers provided at uniform distances from each other throughout the flat panel display.
 39. The flat panel display as recited in claim 38, wherein the plurality of spacers have different heights.
 40. The flat panel display as recited in claim 39, wherein spacers in a center position in the flat panel display are higher than spacers at side positions of the flat panel display.
 41. The flat panel display as recited in claim 37, wherein said at least one spacer is shaped as a rod positioned substantially normal to a top surface plane of said anode.
 42. The flat panel display as recited in claim 37, wherein said at least one spacer has an approximately I-shaped structure.
 43. The flat panel display as recited in claim 37, wherein said at least one spacer has an approximately T-shaped structure.
 44. The flat panel display as recited in claim 43, wherein a wider end portion of the approximately T-shaped structure of said at least one spacer is coupled to said anode.
 45. The flat panel display as recited in claim 43, wherein a wider end portion of the T-shape structure of said at least one spacer is coupled to said cathode.
 46. The flat panel display as recited in claim 37, wherein said anode is a faceplate substrate having a conductive layer formed thereon, and wherein said at least one spacer is formed directly on the faceplate substrate. 